GE Industrial Solutions HPC * Switches New Generation. User s Guide. Note: Fuses are not supplied with the new HPC Switches.

GE Industrial Solutions HPC * Switches New Generation User s Guide Note: Fuses are not supplied with the new HPC Switches.

Getting started Since this switch is available in a variety of configurations, please take a moment to compare the catalog number of your purchased switch with the catalog number key below. Installation of an incorrect switch could result in misapplication, lack of system coordination, or reduced system selectivity. If you have any questions, call the GE Customer Support Center at 800-843-3742. This is not an ordering guide. Order the new generation HPC switch by using the configuration tool to generate a complete switch catalog number. The table below shows the basic switch frames. T H P R 2 3 6 08 T Code Description Function T Legacy ID Designation Product I.D. H Legacy ID designation (High) Product I.D. P Legacy ID Designation Product I.D. (Pressure) R Redesigned smaller size: 800A - Frame size C L 1600A Contact: 2000A - 4000A¹ Long: 42 Long, 4000A only² 2 New generation of switch on Switch generation Power Break* II platform 3 Three poles No. of poles 6 600 VAC Maximum Voltage rating 08 12 16 20 25 30 40 T B 800 A 1200 A 1600 A 2000 A 2500 A 3000 A 4000 A T = Top Feed B = Bottom Feed Maximum Current rating Connection type ¹Replacement only: 800, 1200 & 1600A switches. 36 long per 2000A Outline. Fits in place of 1970 s era HPC i.e. THPC3408, THPC3608, THPC3412, THPC3612, THPC3416, THPC3616 GF and non-gf types. ²L = 42 Long 4000A. Fits in place of old HPC w/ GF i.e. THPC3640G3T or THPC3640BG3T. New Generation HPC switch frame catalog numbering system. Example a switch with catalog number THPR23608T has the following features: New HPC Switch Legacy ID (T) New HPC Switch Legacy ID (H) New HPC Switch Legacy ID (P) Redesigned smaller frame size : 800A-16000A (R) New generation of switch (2) Three poles (3) 600 VAC (6) 800 A (08) Top Feed (T)

WARNINGS, CAUTIONS, AND NOTES AS USED IN THIS PUBLICATION WARNINGS Warning notices are used in this publication to emphasize hazardous voltages, currents, or other conditions that could cause personal injury are present in this equipment or may be associated with its use. Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause either personal injury or damage to equipment. CAUTIONS Caution notices are used for situations in which equipment might be damaged if care is not taken. NOTES Notes call attention to information that is especially significant to understanding and operating the equipment. This document is based on information available at the time of its publication. While efforts have been made to ensure accuracy, the information contained herein does not cover all details or variations in hardware and software, nor does it provide for every possible contingency in connection with installation, operation, and maintenance. Features may be described herein that are not present in all hardware and software systems. GE Industrial Solutions assumes no obligation of notice to holders of this document with respect to changes subsequently made. GE Industrial Solutions makes no representation or warranty, expressed, implied, or statutory, with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warrantees of merchantability or fitness for purpose shall apply. The following are trademarks of the General Electric Company: HPC*, Power Break* II, EntelliGuard* *Trademark of the General Electric Company and/or its subsidiaries. WARNING : Potential arc flash and shock hazard. Turn Off and Lockout power prior to working on equipment. Isolate all energy sources including control power. Completely Discharge closing spring and Open HPC Switch. If front cover will be removed for any reason, be sure to completely Discharge the closing spring again and Open the HPC switch to avoid pinch points and crushing hazards. AVERTISSEMENT : Risque d arc électrique et risque de choc électrique. Arrêter et verrouiller l alimentation avant d effectuer du travail sur l équipement. Isoler toutes les sources d énergie, y compris l alimentation de contrôle. Décharger complètement le ressort de la bobine de fermeture et ouvrir le commutateur HPC. Si le panneau avant est retiré, pour quelconque raison, s assurer de décharger complètement le ressort de la bobine de fermeture et ouvrir le commutateur HPC pour éviter les points de coincement et les risques d écrasement. Copyright 2014 GE Company All Rights Reserved i

Table of Contents Chapter 1-- Introduction 1-1 Overview... 1 1-2 Receiving the Switch... 1 Storage... 1 1-3 Preparation for Installation... 1 Lifting Instructions... 1 Bolted Electrical Connections... 1 Panel Cutouts and Clearances... 2 Enclosures Volume and Ventilation... 5 Accessory Installation... 5 1-4 Switch Installation... 5 Chapter 2-- Operation 2-1 Standard Features... 6 2-2 Operating Instructions... 6 Sequence of Operations... 6 Operating Instructions for Manually Operated Switches... 6 Additional Instructions for Motor-Operated Switches... 8 Padlock Operation... 8 Periodic Operational Checks... 8 Wiring Notes... 8 2-3 Trip Unit Setup... 9 Chapter 3 -- Accessory Operation 3-1 Blown Fuse Protector... 10 3-2 Plug-In Accessory Compartment... 11 3-3 Bell Alarm Alarm Only... 11 Operation... 11 3-4 Bell Alarm with Lockout... 11 Operation... 12 3 5 Shunt Trip with Lockout... 12 Operation... 13 3-6 Undervoltage Release... 13 Operation... 13 3-7 Motor Operator Mechanism... 13 Remote Operation... 14 Automatic Operation... 14 3-8 Remote Close... 14 Remote Operation... 14 3-9 Key Interlock Mounting Provision... 14 Operation... 14 3-10 Mechanical Counter... 15 3-11 Auxiliary Switch Module... 15 ii

Table of Contents Operation... 15 3-12 Door Interlock... 16 Operation... 16 3-13 Push Button Cover... 17 Operation... 17 3-14 Neutral Current Sensors... 17 3-15 Front Connected Terminals... 19 Chapter 4 -- Trouble-Shooting Guide... 20 iii

List of Figures 1. Lifting the new HPC Switch 1 2. Front-panel escutcheon cutout dimensions...2 3. Locations of the front-panel escutcheon cutout and mounting holes, 800A Top Connected frame...... 2 4. Locations of the front-panel escutcheon cutout and mounting holes, 800A Bottom Connected frame...... 2 5. Locations of the front-panel escutcheon cutout and mounting holes, 1200A-1600A Top Connected frame.... 3 6. Locations of the front-panel escutcheon cutout and mounting holes, 1200A-1600A Bottom Connected frame..... 3 7. Locations of the front-panel escutcheon cutout and mounting holes, 2000A Top Connected frame..... 3 8. Locations of the front-panel escutcheon cutout and mounting holes, 2000A Bottom Connected frame..... 3 9. Locations of the front-panel escutcheon cutout and mounting holes, 2500A-3000A, Top Connected frame..... 4 10. Locations of the front-panel escutcheon cutout and mounting holes, 2500A-3000A, Bottom Connected frame..... 4 11. Locations of the front-panel escutcheon cutout and mounting holes, 4000A Top Connected frame..... 4 12. Locations of the front-panel escutcheon cutout and mounting holes, 4000A Bottom Connected frame... 4 13. Enclosure Dimensions, Volume and Ventilation Requirements.... 5 14. Front of the switch, showing the locations of standard features..... 6 15. Side view of the switch, showing the padlock tab extended.... 8 16. Terminal block mounted on the right side of the new HPC Switch... 9 17. Wiring diagram of the Motor Operator Mechanism and Remote Close Accessories.... 9 18. Blown Fuse Trip Provision wiring diagram.... 10 19. Locations of the plug-in accessory modules In the compartment on the front of the switch... 11 20. Bell Alarm Alarm Only module... 11 21. Bell Alarm Alarm Only connections on the right terminal block.... 11 22. Bell Alarm with Lockout module.... 12 23. Bell Alarm with Lockout connections on the right terminal block.... 12 24. Shunt Trip with Lockout module.... 12 25. Undervoltage Release module.... 13 26. Motor Operator Mechanism.... 13 27. Remote Close accessory.... 14 28. Side view of the switch, showing the padlock tab extended with the Key Interlock installed.... 15 29. Mechanical Counter.... 15 30. Auxiliary Switch Module with 12 switches.... 16 31. Auxiliary switch wiring diagram.... 16 32. Door Interlock accessory installed on the switch.... 17 33. Push Button Cover.... 17 34. TSVG Neutral Current Sensor.... 17 iv

List of Figures 35. SSVG Neutral Current Sensor.... 18 36. Wiring Diagram of Neutral Current Sensor for Forward Feed Applications.... 18 37. Wiring Diagram of Neutral Current Sensor for Reverse Feed Applications.... 19 v

List of Tables 1. Weights of the various switch frame sizes, with and without a motor operator.... 1 2. Bolt sizes and mounting torques for bus connections.... 2 3. Enclosure Dimensions, Volume and Ventilation Requirements... 5 4. Sequence of operations that may be performed with new HPC Switches.... 7 5. Accessory connections to the right-side terminal block B.... 9 6. Blown Fuse Protector catalog numbers, factory installed.... 10 7. Bell Alarm Alarm Only catalog numbers, factory installed.... 11 8. Bell Alarm with Lockout catalog numbers, factory installed.... 12 9. Catalog numbers and voltages for the Shunt Trip with Lockout.... 12 10. Catalog numbers and voltages for the Undervoltage Release, factory installed.... 13 11. Catalog numbers and operating voltages for the Motor Operator Mechanism, factory installed.... 14 12. Catalog numbers and operating voltages for the Remote Close accessory, factory installed.... 14 13. Catalog numbers of Key Interlock models.... 14 14. Auxiliary Switch Module catalog numbers, factory installed.... 16 15. Auxiliary switch positions on the terminal board on the left side of the switch, Block A.... 16 16. TSVG Neutral Current Sensor catalog numbers.... 17 17. SSVG Neutral Current Sensor catalog numbers.... 18 18. Front Connected Terminals catalog numbers.... 19 vi

Chapter 1 -- Introduction 1-1 Overview New generation HPC switches are designed to serve lowvoltage power circuits and equipment. They are available with EntelliGuard Trip Units for operation of accessories and optional adjustable instantaneous and ground-fault detection. Basic current metering is standard on all new HPC switches with a trip unit. Class L fuses are not supplied with the new HPC switch. They are Fused Power Circuit Devices UL listed to the UL 977 Standard & bear the CULUS marking for the USA & Canada. The new HPC switch shares many accessories with the GE Power Break II circuit breaker. If the switch is stored for any length of time, it should be inspected periodically to ensure good mechanical condition. 1-3 Preparation for Installation Lifting instructions 1-2 Receiving the Switch Unpack the switch and inspect it for shipping damage. Ensure that the switch has the proper current, voltage, and interruption ratings for the application by comparing the catalog number with the table in the Getting Started section on the inside front page. The weights of the various frame sizes are listed in Table 1, for reference. Frame Rating Operation Type 800 A Manual Electrical 1200 A and Manual 1600 A Electrical 2000 A Manual Electrical 2500 A and 3000 A Manual Electrical 4000 A Manual Electrical Weight (lb) 81 90 95 104 110 119 210 219 400 409 Table 1: Weights of the various switch frame sizes, with and without a motor operator (fuses not included). Storage The switch should be placed in service immediately in its permanent location. However, if it must be stored for an indefinite period, it should be carefully protected against condensation, preferably by storage in a warm dry room. Switches for outdoor equipment should be stored in that equipment only when power is available and heaters are in operation, to prevent condensation. The switch should be stored in a clean location, free from corrosive gases or fumes. In particular, protect the switch from moisture and cement dust, as that combination may be corrosive. Figure 1: Lifting the new HPC switch. These instructions and the packaging of the new HPC Switch are designed to aid with safe removal and mounting of the switch. Adhere carefully to these instructions for protection of personnel and switch. 1. Remove 4 bolts holding switch to pallet. 2. Lift switch into mounting position with hooks placed in lifting holes in back plate. (4 lifting holes provided) Do not attempt to lift switch horizontally by using only two diagonally opposite lifting holes. Bolted Electrical Connections Using an industry-accepted solvent, remove any foreign material from the line and load strap surfaces and the corresponding surfaces of the connecting bus. Ensure that the mating surfaces are smooth and free of burrs and nicks. Place the bus connections in position and align the mounting holes. Insert and fasten the mounting bolts and washers according to specifications in Table 2. 1

Chapter 1 -- Introduction Bus Connection Switch Frame Bolt Diam. Torque (in-lb) 800A (1) 1/2 in. 300 1600-2000A (2) 1/2 in. 300 2500 A (4) 3/8 in. 225 3000 A (4) 3/8 in. 225 4000 A (6) 1/2 in. 300 Table 2: Bolt sizes and mounting torques for bus connections. Panel Cutouts and Clearances Use the following information to prepare the equipment and assure proper clearances for installation and operation of the switch. Figure 3: Locations of the front-panel escutcheon cutout and mounting holes, 800A Top Connected frame. Figure 2: Front-panel escutcheon cutout dimensions (All dimensions are in inches). Figures 3-12 show the front-panel escutcheon cutout patterns and the locations of the switch mounting bolts. The standard door cutout dimensions require a trim plate on the switch. Figure 4: Locations of the front-panel escutcheon cutout and mounting holes, 800A Bottom Connected frame. 2

Chapter 1 -- Introduction Figure 5: Locations of the front-panel escutcheon cutout and mounting holes, 1200A-1600A Top Connected frame. Figure 7: Locations of the front-panel escutcheon cutout and mounting holes, 2000A Top Connected frame. Figure 6.Locations of the front-panel escutcheon cutout and mounting holes, 1200A-1600A Bottom Connected frame. Figure 8: Locations of the front-panel escutcheon cutout and mounting holes, 2000A Bottom Connected frame. 3

Chapter 1 -- Introduction Frame Type A C 17.25 Figure 9: Locations of the front-panel escutcheon cutout and mounting holes, 2500A-3000A Top Connected frame. L 19.25 Figure 11: Locations of the front-panel escutcheon cutout and mounting holes, 4000A Top Connected frame. Frame Type A C 17.25 Figure 10: Locations of the front-panel escutcheon cutout and mounting holes, 2500A-3000A Bottom Connected frame. L 19.25 Figure 12: Locations of the front-panel escutcheon cutout and mounting holes, 4000A Bottom Connected frame. 4

Chapter 1 -- Introduction Enclosures Volume and Ventilation Accessory Installation The following accessories may be installed in the new HPC switch. Refer to Chapter 3 of this publication for catalog numbers and to the instruction sheet supplied with each accessory for installation instructions. Motor Operator Mechanism Remote Close Undervoltage Release Shunt Trip with Lockout Bell Alarm Alarm Only Bell Alarm with Lockout Auxiliary Switch Module Mechanical Counter Key Interlock Mounting Provision Push Button Cover Door Interlock Blown Fuse Protector Figure 13: Enclosure Dimensions, Volume and Ventilation Requirements. Data Min.Volume (Cubic inches) A Min. Ventilation Top and Bottom (5) Square Inches B Min. Line to Grd. (Inches) C Min. Height (Inches) D Width (Inches) E Mounting Depth (Inches) F Min. to Grd. Or Insulation (Inches) 800A 1200A - 1600A Switch Ampere Rating 2000A 2500A 3000A 4000A 6,062 6,495 9,380 9,380 9,380 17,347 23 63 63 172 172 189 2 2 2 2 2 9 28 30 40 40 40 52 25 25 25 25 25 30 8.66 8.66 9.38 9.38 9.38 11.12 3.5 3.5 3 3 3 3 1-4 Switch Installation Ensure that all accessory connections are secure. Line up the bolt holes in the enclosure with the attachment points on the switch, illustrated in Figures 3-12, insert the bolts and tighten. Use nonmagnetic material in the area between the line and load terminals to support the switch. Figure 13 and Table 3 give the enclosure requirements. Table 3: Enclosure Dimensions, Volume and Ventilation Requirements. 5

Chapter 2 -- Operation 2-1 Standard Features New HPC Switches are equipped with the following standard features. The letters are keyed to the switch photograph in Figures 13. A Indicator: ON Red OFF Green B Indicator: CHARGED Yellow DISCHARGED White C D E F G H ON button OFF button Manual charging handle Integral 36-point terminal block (12 auxiliary switches, A-B type), Block A Integral 36-point terminal block (all other connections), Block B Sealable hinged cover I Cover mounting screws (4) J K L M Non-interchangeable fixed rating plug Test set connection port/battery compartment Standard padlock provision Dust-resistant ventilation slots 2-2 Operating Instructions Sequence of Operations The sequence of operations that may be performed on the switch are listed in Table 4. Refer to Chapter 3 for information about accessory operation. Operating Instructions for Manually Operated Switches Charging the Mechanism Springs Pull the operating handle down about 90 (until it stops). Repeat five more times to fully charge the springs. This will not close the switch contacts. The charge indicator will show CHARGED on a yellow background. When the springs are fully charged, the handle locks in the stored position. NOTE: The switch cannot be closed unless the springs are fully charged and the handle is stored fully in. NOTE: La fermeture de l'interrupteurne peut être réalisée à moins que les ressorts soient réarmés tout à fait, et le levier est complètement remis à la position d emmagasinage. Figure 14 : Front of the switch, showing the locations of standard features. 6

Chapter 2 Operation On/Off Indicator Charge Indicator Main Switch Contacts Condition of Charging Springs Next Permissible Operating Function OFF DISCHARGED Open Discharged Mechanism may be charged OFF CHARGED Open Charged Contacts may be closed ON DISCHARGED Closed Discharged Mechanism may be recharged or Contacts may be opened ON CHARGED Closed Charged Contacts may be opened Table 4: Sequence of operations that may be performed with new HPC Switches. Closing the Switch Close the switch contacts with either of the following methods: Depress the ON button on the front of the switch. Energize the (optional) Remote Close accessory by applying rated voltage to terminals 16 and 34 on terminal block B. CAUTION: The main switch contacts cannot be closed if any of the following conditions exist: The Bell Alarm with Lockout was not reset after a ground fault lockout. The Undervoltage Release is not energized. The Shunt Trip with Lockout is energized. These conditions must be reset before the switch can be closed. These conditions will mechanically block all electrical and mechanical means of closing. ATTENTION: Les principaux contacts de l interrupteur ne peuvent pas être fermé si l une des conditions suivantes existe: Si la réarmeture du déclencheur n est pas réalisée après le verrouillage en position ouvert provenant du courant de surcharge. Si le minimum de tension (UVR) n est pas sous tension. Le déclenchement shunt avec blocage est actionné. Ces conditions doivent être réinitialisés avant l'interrupteur peut être fermé. Ces conditions vont bloquer mécaniquement tous les électrique et mécanique moyens de fermer l interrupteur. CAUTION: If the switch latch is held in the tripped position by any of the following conditions and an attempt is made to close the main switch contacts, the mechanism will crash (the closing springs discharge with no motion of the switch contact arms). The switch has been designed and tested to withstand more than 100 crash operations, but repeated attempts to close a locked-out switch will damage the switch mechanism. The Key interlock or padlock is in the locked OFF condition. ATTENTION: Si le cliquet de l'interrupteur est tenu en position de déclenchement dans n importe quelle des conditions suivantes et que l on tente de fermer les contacts de l'interrupteur principal, le mécanisme subira un crash (les ressorts de fermeture se détendent sans que les bras des contacts du disjoncteur ne bougent). L'interrupteur a été conçu et testé pour résister à plus de 100 opérations de type crash, cependant des tentatives répétées ayant pour but de fermer un interrupteur bloqué endommageront le mécanisme de l'interrupteur. Si le verrou de clé ou le cadenas est verrouillé en position OFF. Opening the Switch Open the switch contacts with either of the following methods: Depress the OFF button on the front of the switch. Energize the (optional) Shunt Trip with Lockout accessory or de-energize the (optional) Undervoltage Release accessory. 7

Chapter 2-- Operation Additional Instructions for Motor-Operated Switches Charging the Mechanism Springs The mechanism closing springs may also be charged by the following method: Apply rated control power at terminals 18 & 36. Short terminals 17 and 35 on the right terminal block, with a push button or similar device, for a minimum of five seconds. If power is lost during the charge cycle, finish charging the springs by cycling the charging handle until the indicator shows CHARGED on a yellow background. When the springs are fully charged, the handle locks in the stored position. Automatic Operation Connect terminals 17 and 35 on the terminal block on the right side of the switch with a jumper wire. The Motor Operator will automatically recharge the switch closing springs whenever the switch closes. CAUTION: Do not wire switches for automatic charge and automatic close as this could result in repeated closures into a fault. ATTENTION: Ne pas raccorder les interrupteurs pour la fermeture et la charge automatique car cela pourrait résulter dans des fermetures répétées sur un default electrique. Padlock Operation The padlock prevents the switch from closing by holding the trip latch in the tripped position. To install the padlock, use the following procedure: 1. Open the switch (press the OFF button). 2. Grasp the padlock tab and pull it out until it is fully extended, as illustrated in Figure 15. Note that if the switch contacts are closed, the padlock tab will not extend. 3. Insert the padlock; the switch will not close. As many as three 1 /4" to 3 /8" padlocks may be attached at one time. Figure 15: Side view of the switch, showing the padlock tab extended. Periodic Operational Checks Approximately once a year, verify that the switch is operating correctly by opening and closing the mechanism. Wiring Notes Figure 16 illustrates the terminal block installed on the right side of the switch. Table 5 lists the device connections to the terminal block. Each terminal point will accept the following connections: Bare stripped wire one #12 AWG or two #14 AWG. Ring or spade connectors two per terminal. The terminal screws should be tightened to 7 9 in-lb torque. The left terminal block is blank unless the optional Auxiliary Switch Module accessory is ordered. See Table 16 for the device connections to the Auxiliary Switch Module terminal block. 8

Chapter 2-- Operation Figure 16: Terminal block mounted on the right side of the new HPC Switch. Terminal Terminal 18 Motor Operator + 36 Motor Operator 17 Remote Charge 35 Remote Charge 16 Remote Close + 34 Remote Close 15 Bell Alarm only Com 33 Charge Indicator 14 Bell Alarm only NO 32 Shunt Trip 13 Bell Alarm only NC 31 Shunt Trip 12 Bell Alarm Lockout Com 30 Undervoltage Release 11 Bell Alarm Lockout NO 29 Undervoltage Release 10 Bell Alarm Lockout NC 28 Programmable input + for GF alarm or RELT 9 UVR Indicator com 27 Programmable input - for GF alarm or RELT 8 UVR Indicator N.O. 26 Zone-Select Input 7 comm 25 Zone-Select Input + 6 comm + 24 Zone-Select Output 5 C Phase Volts 23 Zone-Select Output + 4 B Phase Volts 22 Programmable output - for GF alarm or RELT 3 A Phase volts 21 Programmable output+ for GF alarm or RELT 2 24 Vdc 20 Neutral Hi/Low Tap 1 24 Vdc + 19 Neutral common Tap Do not apply voltage; see wiring diagram (Figure 16).Place a jump wire from terminal 17 to terminal 35 for automatic charge If RELT is provided on the Trip Unit, GF alarm cannot be the programmed output. GF alarm can however be communicated on Modbus if the trip unit has communication capability Figure 17: Wiring diagram of the Motor Operator Mechanism and Remote Close accessories. 2-3 Trip Unit Setup See DEH 4567 for detailed instructions on setting up the EntelliGuard TU Trip Unit. Table 5: Accessory connections to the right-side terminal block B. 9

Chapter 3 -- Accessory Operation 3-1 Blown Fuse Protector The Blown Fuse Protector (factory installed) is an accessory which includes components mounted on and external to the new HPC Switch. Control wiring is connected from one end of each fuse mounting bus-strap to a 6 pt. terminal block mounted on the side of the new HPC Switch. A shunt trip Lockout device or UVR trip device is included based on the Catalog No. s below for remote opening of the new HPC switch in the event of a blown fuse to avoid single phasing. The accessory also includes a pin-wheel style Blown Fuse Detector equipped with 3 trigger fuses + 1 spare. Wiring from the pin-wheel device to the new HPC switch is the responsibility of the switchboard builder. Catalog Number (factory installed) Catalog Number (field installed kit)¹ Trip Accessory Provided Operating Voltage BFSPSTL120AC BFSPSTL120ACR SPSTL120 120VAC BFSPSTL208AC BFSPSTL208ACR SPSTL208 208VAC BFSPSTL240AC BFSPSTL240ACR SPSTL240 240VAC BFSPUV120AC BFSPUV120ACR SPUV120AC 120VAC BFSPUV208AC BFSPUV208ACR SPUV208AC 208VAC BFSPUV240AC BFSPUV240ACR SPUV240AC 240VAC Table 6: Blown Fuse Protector catalog number. Operation: If any of the Class L fuses opens on the new HPC switch, the trigger fuse wired across the Class L fuse will blow and the trigger will rotate the pin wheel to operate a microswitch with both NO and NC contacts. The microswitch is used to switch externally provided control power to the shunt trip lockout or UVR to open the new HPC Switch. Replacement of blown Class L fuses and trigger fuses will be necessary. Mersen/Shawmut trigger fuse TI-600 or Bussman KAZ trigger fuses are used. Figure 18: Blown Fuse Protector Wiring Diagram. ¹For field installable kits only, the Pin wheel style Blown Fuse Detector is not included due to UL accessory listing requirements. Source the Boltswitch PW-2 Blown Fuse Detector separately and follow that manufacturer s instructions for mounting and use. 10

Chapter 3 -- Accessory Operation 3-2 Plug-In Accessory Compartment Several of the accessories are installed in the accessory compartment on the front of the switch. Figure 19 illustrates this compartment and the locations of each of the plug-in accessory modules. Figure 19.Locations of the plug-in accessory modules in the compartment on the front of the switch. Catalog No. Contact Rating SPBAA240 6 A at 240 Vac 0.25 A at 250 Vdc 0.50 A at 125 Vdc SPBAA600 6 A at 600 Vac 0.25 A at 250 Vdc 0.50 A at 125 Vdc 600 V version is not UL listed. Table 7: Bell Alarm Alarm Only catalog numbers, factory installed. Operation The Bell Alarm Alarm Only provides normally open (NO) and normally closed (NC) outputs available at the terminal block on the right side of the switch, as illustrated in Figure 21. The outputs change state whenever a new HPC Switch trips open by means of the trip unit detecting a fault, either instantaneous or ground fault. The Bell Alarm Alarm Only accessory resets automatically, returning the outputs to their normal configuration, when the new HPC Switch is reclosed. The Bell Alarm Alarm Only can also be reset manually, before the switch is reclosed, by pressing the reset button on the front of the module. 3-3 Bell Alarm Alarm Only The Bell Alarm Alarm Only module, shown in Figure 20, provides a switch to remotely indicate that the switch has tripped. It is reset either automatically when the switch is reclosed or manually by firmly pressing the yellow button on the front of the Bell Alarm Alarm Only module. Figure 21: Bell Alarm Alarm Only connections on the right terminal block. The contacts are shown in the reset state. Figure 20: Bell Alarm Alarm Only module. The Trip Unit activates the Bell Alarm Alarm Only for protection trips only. The catalog numbers for the Bell Alarm Alarm Only (factory installed) are listed in Table 7. For installation instructions see GEH 6275. 3-4 Bell Alarm with Lockout The Bell Alarm with Lockout module, shown in Figure 22, prevents reclosing of the switch after a protective trip until the Bell Alarm with Lockout is reset. It can only be reset by firmly pressing the yellow button on the front of the module. This module also provides a switch to remotely indicate that the new HPC Switch has tripped. The Trip Unit activates the Bell Alarm with Lockout for protection trips only. The catalog numbers for the factory installed Bell Alarm with Lockout (factory installed) are listed in Table 8. For installation instructions see GEH 6278. 11

Chapter 3 -- Accessory Operation 3 5 Shunt Trip with Lockout The Shunt Trip with Lockout module, shown in Figure 24, allows the switch to be opened electrically from a remote location and prevents the switch from closing while the accessory is energized. Figure 22 : Bell Alarm with Lockout module. Catalog No. Contact Rating SPBAL240 6 A at 240 Vac 0.25 A at 250 Vdc 0.50 A at 125 Vdc SPBAL600 6 A at 600 Vac 0.25 A at 250 Vdc 0.50 A at 125 Vdc The 600 V version is not UL listed. Table 8: Bell Alarm with Lockout catalog numbers, factory installed. Operation The Bell Alarm with Lockout prevents reclosing of the switch after a protective trip until the yellow reset button on the front of the module is pressed. This trip can be caused by a ground fault condition or instantaneous fault detected by the Trip Unit. In addition, the Bell Alarm with Lockout provides normally open (NO) and normally closed (NC) alarm outputs available at the terminal block on the right side of the switch, as illustrated in Figure 23. These outputs are returned to their normal state when the Bell Alarm with Lockout yellow reset button is firmly pressed. Figure 23: Bell Alarm with Lockout connections on the right terminal block. The contacts are shown in the reset state. Figure 24: Shunt Trip with Lockout module. If the switch is equipped with a Trip Unit, it is configured so that only protective trips will activate a Bell Alarm Alarm Only or Bell Alarm with Lockout. The catalog numbers for the Shunt Trip s with Lockout (factory installed) for various voltage applications are listed in Table 9. For installation instructions see GEH 6284 or GEH 6519. Catalog Number Voltage Rating Peak Inrush Current, A Nominal RMS Current, ma SPSTL012 12 Vdc 19 300 SPSTL024 24 Vac 24 Vdc 15 300 SPSTL048 48 Vac 48 Vdc 7.5 200 SPSTL120 120 Vac 125 Vdc 3.0 80 SPSTL208 208 Vac 1.9 60 SPSTL240 240 Vac 250 Vdc 1.5 45 SPSTL480 480 Vac 0.75 20 SPSTL600 600 Vac 0.60 16 24 600 Vac devices are rated for 50/60 Hz. Peak inrush current is present for 2 6 ms after activation. This number is provided so that fuses and supplies can be chosen appropriately. Ratings for 480 Vac and 600 Vac devices are at the input of the upstream transformer, included with the accessory and specified in GEH 6519, which powers the device. For voltage and current ratings at the switch terminal block, see SPSTL120. Table 9: Catalog numbers and voltages for the Shunt Trip with Lockout, factory installed. 12

Chapter 3 -- Accessory Operation Operation Apply control voltages to terminals 31 and 32 of the terminal strip on the right side of the switch to open the switch. The Shunt Trip with Lockout will cause the switch to open when the control voltage is greater than 75% of the dc-rated value or 55% of the ac-rated value. 3-6 Undervoltage Release The Undervoltage Release (UVR) module, shown in Figure 25, opens the switch when the input control voltage drops to 35 60% of its rated value and prevents an open switch from closing until the input control voltage is greater than 80% of the rated value. If the switch is equipped with a Trip Unit, it is configured so that only protective (ground fault or instantaneous) trips will activate a Bell Alarm Alarm Only or Bell Alarm with Lockout. Figure 25: Undervoltage Release module. The catalog numbers for the UVR (factory installed) for various voltage applications are listed in Table 10. For installation instructions see GEH-6285 or GEH 6520. Catalog Number Voltage Rating Peak Inrush Current, A Nominal RMS Current, ma SPUV012DC 12 Vdc 19 300 SPUV024DC 24 Vdc 15 140 SPUV048DC 48 Vdc 7.5 70 SPUV125DC 125 Vdc 3 30 SPUV250DC 250 Vdc 1.5 15 SPUV024AC 24 Vac 15 370 SPUV048AC 48 Vac 7.5 210 SPUV120AC 120 Vac 3 80 SPUV208AC 208 Vac 1.9 60 SPUV240AC 240 Vac 1.5 45 SPUV480AC 480 Vac 0.75 20 SPUV600AC 600 Vac 0.60 16 24 600 Vac devices are rated for 50/60 Hz. Peak inrush current is present for 2 6 ms after activation. This number is provided so that fuses and supplies can be chosen appropriately. Ratings for 480 Vac and 600 Vac devices are at the input of the upstream transformer, included with the accessory and specified in GEH 6520, which powers the device. For voltage and current ratings at the switch terminal block, see SPUV120AC. Table 10: Catalog numbers and voltages for the Undervoltage Release, factory installed 3-7 Motor Operator Mechanism The Motor Operator Mechanism, shown in Figure 26, provides a means of remotely or automatically charging the springs that close the switch. Table 11 lists the catalog numbers for the available Motor Operator Mechanism models. For installation instructions see GEH-6281. Operation Apply control voltage to terminals 29 and 30 of the terminal strip on the right side of the switch. When the applied control voltage is above 80% of the UVR s rated value, the switch can be closed. When the voltage drops to 35 60% of the rated value, the UVR will open the switch. Figure 26: Motor Operator Mechanism. 13

Chapter 3 -- Accessory Operation Catalog No. SPE024 SPE048 SPE072 SPE120 SPE125 SPE240 Voltage Rating 24 Vdc 48 Vdc 72 Vdc 120 Vac 125 Vdc 240 Vac Table 11:. Catalog numbers and operating voltages for the Motor Operator Mechanism, factory installed Remote Operation The switch closing springs can be charged remotely by shorting terminals 17 and 35 on the terminal block on the right side of the switch, with a push button or similar device, for a minimum of five seconds while rated control power is applied at terminals 18 and 36. Automatic Operation Connect terminals 17 and 35 on the terminal block on the right side of the switch with a jumper wire. The Motor Operator will automatically recharge the switch closing springs whenever the switch closes. CAUTION: Do not wire switches for automatic charge and automatic close as this could result in repeated closures into a fault. ATTENTION: Ne pas raccorder les interrupteurs pour la fermeture et la charge automatique car cela pourrait résulter dans des fermetures répétées sur un default electrique. 3-8 Remote Close The Remote Close accessory, shown in Figure 27, provides a means of remotely closing the switch after the springs have been charged. Table 12 lists the catalog numbers for the available models. For installation instructions see GEH-6283. Remote Operation The switch can be closed remotely, provided that the springs are charged, by applying the rated voltage to terminals 16 and 34 on the terminal block on the right side of the switch. The Remote Close accessory is continuously rated and has an anti-pump feature that prevents a motor-operated switch from repeatedly closing into a fault. Closing control voltage must be removed and reapplied for each switch closure. Figure 27: Remote Close accessory. Catalog No. SPRCS024 SPRCS048 SPRCS072 SPRCS120 SPRCS125 SPRCS240 Voltage Rating 24 Vdc 48 Vdc 72 Vdc 120 Vac 125 Vdc 240 Vac Table 12: Catalog numbers and operating voltages for the Remote Close accessory, factory installed 3-9 Key Interlock Mounting Provision The Key Interlock Mounting Provision provides mounting for one to four key locks. The GE catalog number is SPK4 (factory installed). The key locks must have a zero extension when the bolt is withdrawn with 0.75-inch extension when the bolt is extended. The lock may be up to 1.50 inch wide. Catalog numbers for suitable locks from Kirk Key Interlock Co. and Superior Interlock Co. are listed in Table 13. For installation instructions see GEH-6279. # Locks Kirk Key Cat. No. Superior Cat. No. Approx. Lock Length 1 KFN00001_ S105827Y 2.38" 2 KFN00002_ S105828Y 3.38" 3 KFN00003_ S105829Y 4.38" 4 KFN00004_ S105827-4Y 5.48" Final digit may be 0, 1, 2, or 3 depending on key removable positions. Table 13: Catalog numbers of Key Interlock models. Operation The Key Interlock prevents the switch from closing by holding the padlock tab extended, thus keeping the trip latch in the tripped position. A secondary padlock lever is included with the Key Interlock, since the Key Interlock 14

Chapter 3 -- Accessory Operation blocks easy access to the standard padlock hasp. To operate, use the following procedure: 1. Open the switch (press the OFF button). 2. Grasp the padlock tab and pull it out, as illustrated in Figure 29. Note that if the switch contacts are closed, the padlock tab will not pull out. 3. Turn the key, securing the padlock tab in the extended position. The switch cannot be closed until the Key Interlock is disengaged. 4. Rotate the secondary padlock lever out and assemble padlocks as desired. 3-10 Mechanical Counter The Mechanical Counter, shown in Figure 29, counts the number of times the switch is closed. The catalog number of the factory installed Mechanical Counter is SPCOUNTER (factory installed). For installation instructions see GEH-6280. Figure 29: Mechanical Counter. Figure 28: Side view of the switch, showing the padlock tab extended with the Key Interlock installed. CAUTION: Repeated attempts to close a locked-out switch will damage the switch mechanism. ATTENTION: Les tentatives à maintes fermer un interrupteur verrouillê en position ouvert endommageront le mêcanisme de l'commutateur. 3-11 Auxiliary Switch Module The Auxiliary Switch Module, shown in Figure 30, provides remote indication of the new HPC Switch main contact position through the terminals on the terminal block on the left side of the switch. Auxiliary Switch Modules are available with 4, 8, and 12 switches with ratings of 6 A at 240 Vac or 600 Vac. Additional ratings of 0.5 A at 125 Vdc and 0.25 A at 250 Vdc apply to all models. Catalog numbers are listed in Table 14. For installation instructions see GEH-6274. Operation Each auxiliary switch provides two outputs that can be used to indicate switch main contact position. The A output is open or closed the same as the switch, while the B output is the opposite to the new HPC switch contacts. Figure 32 is a wiring diagram of each auxiliary switch. The connections for the auxiliary switch outputs are found on the terminal block on the left side of the switch and are listed in Table 16. 15

Chapter 3 -- Accessory Operation Figure 30: Auxiliary Switch Module with 12 switches. # Switches 240 Vac 600 Vac 4 SPAS240AB4 SPAS600AB4 8 SPAS240AB8 SPAS600AB8 12 SPAS240AB12 SPAS600AB12 600 Vac devices are not UL listed. Table 14 : Auxiliary Switch Module catalog numbers, factory installed. Terminal (upper) Terminal (lower) 1 Auxiliary 12 A 19 Auxiliary 11 A 2 Auxiliary 12 B 20 Auxiliary 11 B 3 Auxiliary 12 common 21 Auxiliary 11 common 4 Auxiliary 10 A 22 Auxiliary 9 A 5 Auxiliary 10 B 23 Auxiliary 9 B 6 Auxiliary 10 common 24 Auxiliary 9 common 7 Auxiliary 8 A 25 Auxiliary 7 A 8 Auxiliary 8 B 26 Auxiliary 7 B 9 Auxiliary 8 common 27 Auxiliary 7 common 10 Auxiliary 6 A 28 Auxiliary 5 A 11 Auxiliary 6 B 29 Auxiliary 5 B 12 Auxiliary 6 common 30 Auxiliary 5 common 13 Auxiliary 4 A 31 Auxiliary 3 A 14 Auxiliary 4 B 32 Auxiliary 3 B 15 Auxiliary 4 common 33 Auxiliary 3 common 16 Auxiliary 2 A 34 Auxiliary 1 A 17 Auxiliary 2 B 35 Auxiliary 1 B 18 Auxiliary 2 common 36 Auxiliary 1 common Table 15: Auxiliary switch positions on the terminal board on the left side of the switch, Block A. 3-12 Door Interlock The Door Interlock, shown in Figure 32, prevents the casual opening of the enclosure door, particularly while the new HPC Switch is ON. The catalog number of the factory installed Door Interlock is SPDIL (factory installed). For installation instructions see GEH-6276. Operation The Door Interlock prevents the opening of the enclosure door unless the locking lever is disengaged. The lever can be disengaged easily with the switch OFF or with somewhat greater difficulty with the switch ON, as described below. Figure 31: Auxiliary switch wiring diagram. Opening Door with Switch Off To open the enclosure door when the switch is OFF, pull up on the padlock tab and slide the Door Interlock lever counter-clockwise until it no longer obstructs the door. When the door is reclosed, simply slide the lever back into the locking position. 16

Chapter 3 -- Accessory Operation 3-14 Neutral Current Sensors When the ground-fault option is selected in a trip unit for a 3 phase 4-wire power system (e.g.120/208vac or 277/480 VAC), an external neutral sensor must be inserted in the neutral lead of the power system to complete the groundfault protective circuit. Figure 32: Door Interlock accessory installed on the switch. Opening Door with Switch On The Door Interlock can be defeated, to allow opening the enclosure door with the switch ON, even though the padlock tab cannot be lifted. Depress the interlock spring with a screwdriver in the slot on the top of the locking lever and push the lever counter-clockwise to disengage it from the spring. Remove the screwdriver; then continue rotating the locking lever until it clears the door. 3-13 Push Button Cover The Push Button Cover, shown in Figure 33, prevents accidental or unauthorized closing or opening of the switch with the local push buttons. It consists of two unbreakable, individually sealable Lexan shields, one over the PUSH ON button and one over the PUSH OFF button. The catalog number is SPPBCOVER (factory installed). For installation instructions see GEH-6282. Operation Close the cover and put a sealing wire or wire tie in the slot. Each of the covers may be sealed independently. Figure 34: TSVG Neutral Current Sensor. Neutral Current Sensors HPC Switch Sensor Rating (Amps) Neutral Sensor rating or tap Settings (Amps) Catalog Number of sensor mounted on copper busbars 800 800 800/400 TSVG308A 1200 1200 1600 1200/600 TSVG812A TSVG816A 1600/1000 1600 1600 1600/1000 TSVG816A 2000 2000 2000/1200 TSVG820A 2500 2500 2500/1800 TSVG825A 3000 3000 3000/2400 TSVG830A 4000 4000 4000/3000 TSVG940A Match neutral current sensor rating (or tap setting) to new HPC Switch sensor rating. At time of initial product release, the 1200A new HPC Switch was using 1600A installed sensors and a 1200A rating plug. Later models may use 1200A phase sensors. Match Neutral sensor tap to HPC sensor rating. Outline Drawings 139C5016SH1 & SH2. Table 16: TSVG Neutral Current Sensor catalog numbers. Figure 33: Push Button Cover. 17

Chapter 3 -- Accessory Operation See DETAIL A X1 X2 X1 Common X2 Hi TAP X3 Low TAP X3 DETAIL A LINE SIDE (POTTING) LOAD SIDE Figure 35: SSVG Neutral Current Sensor. Neutral Current Sensors B20 See Notes HPC Switch Frame (Amps) HPC Switch Sensor Rating (Amps) Neutral Sensor rating or tap Settings (Amps) Catalog Number of Window Sensor Inside Diameter (inches) 800 800 800/400 SSVG808W 4.25 1200 1200 2 2000/1200 SSVG820W 5.63 1600 2 1600/1000 SSVG816W 5.63 1600 1600 1600/1000 SSVG816W 5.63 2000 2000 2000/1200 SSVG820W 5.63 2500 2500 2500/1800 SSVG825W 5.63 3000 3000 4000/3000 SSVG940W 6.50 4000 4000 4000/3000 SSVG940W 6.50 Match neutral current sensor rating (or tap setting) to new HPC Switch sensor rating. At time of initial product release, the 1200A new HPC Switch was using 1600A installed sensors and a 1200A rating plug. Later models may or may not use 1200A phase sensors. Match Neutral sensor tap to HPC sensor rating. Outline Drawing 10112973P1. Table 17: SSVG Neutral Current Sensor catalog numbers. L O A D B19 X2/X3 Note: In forward fed applications, the potting side of the CT should face the transformer. X2 is high tap setting and X3 is low tap setting. Select tap setting to match switch sensor. Reference table 17 of DEH 41689. Note that 1200A frame uses 1600A sensor. In all other cases the frame size matches the sensor. X1 N Figure 36: Wiring Diagram of Neutral Current Sensor for Forward Feed Applications 18

Chapter 3 -- Accessory Operation L O A D N B20 See Notes X2/X3 B19 X1 Note: In reverse fed applications, the potting side of the CT should face the load. X2 is high tap setting and X3 is low tap setting. Select tap setting to match switch sensor. Reference table 17 of DEH 41689. Note that 1200A frame uses 1600A sensor. In all other cases the frame size matches the sensor. Figure 37: Wiring Diagram of Neutral Current Sensor for Reverse Feed Applications 3-15 Front Connected Terminals Terminals bolt directly to the line or load terminals of the Breaker. Order one Terminal per line or load pole. Terminals Catalog numbers and ratings are listed in Table 18. Max Amp Rating Voltage Rating 800-2000 SP20FCC 2000 SPS20FCA 2500 SPS25FCC 3000 SPS30FCC 4000 SPS40FCC 4000 SPS40LFCC Copper. Aluminum. Extra-long terminals, alternate with SPS40FCC for ease of installation. Table 18: Front Connected Terminals catalog numbers 19

Chapter 4 -- Trouble-Shooting Guide The following guide is provided for trouble-shooting and isolating common problems. It does not cover every possible situation. Contact the GE Industrial Solutions Customer Support Center at 800-843-3742 if any problem is not resolved by these procedures. Symptom Possible Cause Corrective Action 1. The switch does not close when the ON button is pressed and there is no sound of the closing spring releasing. The closing spring is not fully charged. The Bell Alarm with Lockout is deployed. The Undervoltage Release is not energized. The Trip Unit is not properly installed. On a manually operated switch, operate the handle until the indicator shows CHARGED. On an electrically operated switch, check that the voltage to the motor operator is at least 85% of nominal. See GEH 6281, Motor Operator Mechanism. If the motor ran full cycle but the CHARGE indicator did not drop, cycle the manual charging handle one time. Contact customer support for logic adjustment procedure. Correct the condition that initiated the bell alarm, then firmly depress the yellow plunger on the Bell Alarm with Lockout module to reset the lockout. See GEH 6278, Bell Alarm with Lockout. See GEH 6285, Undervoltage Release, for details on energizing the UVR. See DEH 4567, Trip Unit installation procedure. Follow the Power Break II Trip Unit procedure. 2. The switch does not close when the ON button is pressed, but the closing spring is heard to release. The Trip Unit detected a fault and immediately tripped the switch. The Shunt Trip w/lockout is energized. The switch is locked in the OFF position by a padlock or key interlock. Clear the fault, then recharge the closing spring and close the switch. For fault diagnostics, see DEH 4567, See GEH 6284 & GEH-6519, Shunt Trip & Shunt Trip w/lockout, for instructions on de-energizing the unit. After ensuring that the safety reason for locking the switch no longer applies, remove the padlock or key interlock. See GEH-6279, Key Interlock Mounting Provision. 3. The switch can be opened locally, but not remotely. There is a problem with the Shunt Trip w/lockout. There is a problem with the Undervoltage Release. See the trouble-shooting instructions in GEH 6284 & GEH-6519, Shunt Trip & Shunt Trip w/lockout. See the trouble-shooting instructions in GEH 6285, Undervoltage Release. 20

Chapter 4 --Trouble-Shooting Guide For any other problems related to new HPC Switch accessories, consult the corresponding User s Guide: GEH 6274, Auxiliary Switch Module GEH 6275, Bell Alarm Alarm Only GEH 6276, Door Interlock GEH 4546, Lugs & Adapters for 800 2000 A Frames GEH 6278, Bell Alarm with Lockout GEH 6279, Key Interlock Mounting Provision GEH 6280, Mechanical Counter GEH 6281, Motor Operator Mechanism GEH 6282, Push Button Cover GEH 6283, Remote Close GEH 6284, Shunt Trip and Shunt Trip with Lockout (except 480 and 600 Vac) GEH 6519, Shunt Trip and Shunt Trip with Lockout, 480 & 600 Vac GEH 6285, Undervoltage Release (except 480 and 600 Vac) GEH 6520, Undervoltage Release, 480 & 600 Vac DEH 41694, Instructions, HPC* Heat Sink Installation DEH 41695, Instructions, HPC* Blown Fuse Protector DEH 4567, EntelliGuard* TU Trip Unit Outline Drawings: 10112083P1: 800A Top Feed HPC Switch 10112083P2: 800A Bottom Feed HPC Switch 10112083P3: 1200/1600A Top Feed HPC Switch 10112083P4: 1200/1600A Bottom Feed HPC Switch 10112083P5: 2000A Top Feed HPC Switch 10112083P6: 2000A Bottom Feed HPC Switch 10112083P7: 2500/3000A Top Feed HPC Switch 10112083P8: 2500/3000A Bottom Feed HPC Switch 10112083P11: 4000A Top Feed HPC Switch 10112083P12: 4000A Bottom Feed HPC Switch 22

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